Heat exchanger assembly with vortex flow baffle

ABSTRACT

A cooling system of an internal combustion engine system includes an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing through the internal combustion engine system. The cooling system also includes a heat exchanger assembly positioned along the engine cooling circuit. The heat exchanger assembly is structured to transfer heat from the engine coolant fluid to a working fluid and includes a shell defining an inner cavity, a core disposed within the inner cavity and structured to receive the working fluid, and a main flow path and a bypass flow path of the engine coolant fluid, the core comprising a baffle in the bypass flow path, the baffle including: a base portion coupled to an end of the core and a curved portion extending from the base portion such that the curved portion impedes a bypass flow of engine coolant fluid from continuing along the bypass flow path.

TECHNICAL FIELD

The present disclosure relates generally to cooling systems of internal combustion engine systems.

BACKGROUND

In internal combustion engine systems, cooling systems utilizing heat exchanger assemblies (also referred to as heat exchangers) reduce the temperature of coolant by dissipating heat from the coolant to another fluid flowing through a core of the heat exchanger assembly. However, coolant that passes through the heat exchanger assembly without contacting the core thereof (e.g., bypass flow) does not contribute to heat transfer.

One solution for minimizing or otherwise reducing bypass flow is to attach baffles, e.g., rubber baffles, to the core to reduce or close a gap between the core and a wall of the heat exchanger assembly. However, attaching the baffles to the core close enough to the wall to prevent bypass flow requires tight tolerance dimensions, potentially resulting manufacturing and assembly difficulties. Other solutions such as increasing a size of the core may lead to increased manufacturing costs.

SUMMARY

Various embodiments relate to assemblies and methods for managing bypass flow in a cooling system of an internal combustion engine system. In various embodiments, a heat exchanger assembly includes a baffle having a curved portion for reducing bypass flow. Various embodiments and implementations of such assemblies and methods may provide for reduced bypass flow around a core of the heat exchanger assembly, with the potential for enhanced cooling efficiency.

In at least one embodiment, a cooling system of an internal combustion engine system is provided. The cooling system includes an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing through the internal combustion engine system; and a heat exchanger assembly positioned along the engine cooling circuit and structured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly including: a shell defining an inner cavity, a core disposed within the inner cavity and structured to receive the working fluid, and a main flow path and a bypass flow path of the engine coolant fluid, the core comprising a baffle in the bypass flow path, the baffle including: a base portion coupled to an end of the core, and a curved portion extending from the base portion such that the curved portion impedes a bypass flow of engine coolant fluid from continuing along the bypass flow path.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only, and are not restrictive of the present teachings.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements unless otherwise indicated, in which:

FIG. 1 is a block diagram of a cooling system including a heat exchanger assembly, according to an exemplary embodiment;

FIG. 2 is a perspective view of a heat exchanger assembly with the shell removed which may be used, for example, in the cooling system of FIG. 1 , according to an exemplary embodiment;

FIG. 3 is a side view of the heat exchanger assembly of FIG. 2 with the shell removed;

FIG. 4 is a perspective view of Detail A of the heat exchanger assembly, as seen in FIG. 3 ;

FIG. 5 is a side view of Detail A of the heat exchanger assembly;

FIG. 6 is an illustration of Detail B of the heat exchanger assembly in FIG. 2 , showing an engine coolant fluid flowing through the heat exchanger assembly, according to an exemplary embodiment; and

FIG. 7 is a cross-sectional view of the heat exchanger assembly taken along line 7-7 of FIG. 2 .

DETAILED DESCRIPTION

Following below are more detailed descriptions of various concepts related to, and implementations of, assemblies, apparatuses, and methods for providing a cooling system of an internal combustion engine system. The cooling system includes a heat exchanger assembly structured to transfer heat from an engine coolant liquid to a working fluid. The various concepts introduced above and discussed in greater detail below may be implemented in any of a number of ways, as the described concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

I. Overview

Various implementations described herein are related to a cooling system of an internal combustion engine system. The cooling system includes an engine cooling circuit including an engine coolant fluid. The cooling system also includes a heat exchanger assembly positioned along the engine cooling circuit. The heat exchanger assembly is structured to transfer heat from the engine coolant fluid to a working fluid. The heat exchanger assembly includes a shell defining an inner cavity, a core disposed within the inner cavity and structured to receive the working fluid, an inlet port fluidly coupled to the inner cavity and structured to provide the engine coolant fluid to the inner cavity, an outlet port fluidly coupled to the inner cavity, and a baffle including a base portion coupled to an end of the core and a curved portion extending from the base portion.

II. Cooling System

FIG. 1 depicts a block diagram illustrating an engine system 100 according to an exemplary embodiment. The engine system 100 includes a cooling system 101 comprising an engine cooling circuit 102 and a heat exchanger assembly 118. The engine system 100 may also include an engine 104 having an engine block 106 and an engine overhead 108, a turbocharger 110, a coolant reservoir 112, a pump 114, a valve 116, a heat exchanger assembly 118, and a coolant filter 144. As discussed in further below, the engine cooling circuit 102 defines a flow path and direction for engine coolant fluid flowing through the internal combustion engine system. In some embodiments, the flow path includes channels (e.g., flow path inlets, flow path outlets, conduits, etc.) fluidly coupling the components of the engine system 100. In some embodiments, the engine coolant fluid may include a glycol-based coolant, water, or other coolant fluids. In other embodiments, the engine coolant fluid is a thermal oil or other type of heat transfer fluid. It should also be noted that the terms “upstream” and “downstream” when referring to the engine system 100 refer to a direction of the engine coolant fluid flowing through the engine cooling circuit 102.

Referring to FIG. 1 , the engine system 100 includes an engine 104. The engine 104 may be any type of internal combustion engine. Thus, the engine 104 may be a gasoline, natural gas, or diesel engine, a hybrid engine (e.g., a combination of an internal combustion engine and an electric motor), and/or any other suitable engine. The engine 104 includes an engine block 106. The engine block 106 may at least partially define one or more cylinders of the engine. The one or more cylinders are configured to allow one or more pistons to move within combustion chambers of the cylinders. The engine 104 also includes an engine overhead 108. The engine overhead 108 is positioned above the engine block 106 and may include, for example, an inlet valve, an exhaust valve, and one or more camshafts.

The engine system 100 of FIG. 1 includes a turbocharger 110 downstream of the engine block 106. The turbocharger 110 receives exhaust gases produced by combustion in the engine block 106. In some embodiments, the turbocharger 110 includes a bypass that is operable to selectively bypass at least a portion of the exhaust gases from the turbocharger 110 to reduce boost pressure and engine torque under certain operating conditions. The turbocharger 110 may be positioned on the engine cooling circuit 102, thereby being configured to receive the engine coolant liquid from the engine. The engine coolant liquid may be utilized by the turbocharger 110 to lubricate internal components (e.g., bearings, spindles, etc.).

The engine system 100 of FIG. 1 includes a coolant reservoir 112 (e.g., a pan, an oil pan, etc.) positioned on the engine cooling circuit 102 downstream of the engine overhead 108 and the turbocharger 110. The coolant reservoir 112 is fluidly coupled to engine overhead 108 and the turbocharger 110 via the engine cooling circuit and is configured to receive and store engine coolant fluid therefrom.

The engine coolant fluid received and stored in the coolant reservoir 112 may be later recirculated within the cooling system. For example, the engine system 100 may include a coolant pump 114. In some embodiments, the coolant pump 114 is disposed downstream of the coolant reservoir 112. The coolant pump 114 is structured to circulate the engine coolant fluid through the engine cooling circuit 102.

The engine system 100 of FIG. 1 also includes a valve 116 (e.g., a regulator valve, etc.) positioned on the engine cooling circuit 102. The valve 116 may be positioned downstream of the coolant pump 114. In some embodiments, the valve 116 controls an amount of engine coolant fluid that flows through the engine cooling circuit. More specifically, the valve 116 controls an amount of engine coolant fluid that flows through the heat exchanger assembly 118, as discussed in further detail below. The valve 116 may control the engine coolant fluid by limiting or blocking engine coolant fluid from flowing to the heat exchanger assembly 118.

The heat exchanger assembly 118 of FIG. 1 is positioned downstream of the valve 116 and is structured to transfer heat energy from the engine coolant fluid in the engine cooling circuit 102 to the working fluid so as to cool the engine coolant fluid and heat the working fluid. FIG. 2 is a perspective view of an example heat exchanger assembly 118, according to an exemplary embodiment. FIG. 3 is a side view of the heat exchanger assembly 118 of FIG. 2 . FIG. 4 is a perspective view of Detail A of the heat exchanger assembly 118, as seen in FIG. 3 . FIG. 5 is a side view of Detail A of the heat exchanger assembly 118. FIG. 6 is an illustration of an engine coolant fluid flowing through the heat exchanger assembly 118 of FIG. 2 , according to an exemplary embodiment.

The engine system 100 of FIG. 1 may also include a coolant filter 144 (e.g., an oil filter, etc.). The coolant filter 144 may be positioned between the heat exchanger assembly 118 and the engine 104. The coolant filter 144 is configured to filter 144 particulates (e.g., soot, metallic particles, etc.) from the engine coolant liquid such that the engine coolant liquid exiting the coolant filter 144 contains less particulates than the engine coolant liquid entering the engine coolant liquid filter 144 (e.g., flowing from the heat exchanger assembly 118, etc.). In this way, the coolant filter 144 also inhibits or reduces infiltration of particulates to the engine 104 downstream of the coolant filter 144, thereby facilitating prolonged operation of or reduced maintenance needs for the engine 104.

III. Configuration of Example Heat Exchanger Assembly

Referring to FIGS. 2, 6, and 7 , the heat exchanger assembly 118 includes a shell 120 (e.g., housing, casing, enclosure, etc.). The shell 120 encloses internal components of the heat exchanger assembly 118. In this way, the shell 120 protects internal components of the heat exchanger assembly 118 and reduces exposure of other components of the internal combustion engine system to high temperatures.

By enclosing internal components of the heat exchanger assembly 118, the shell 120 defines an inner cavity 122. The inner cavity 122 is structured to receive the engine coolant fluid provided through the engine cooling circuit by the pump 114. Specifically, the inner cavity 122 receives the engine coolant fluid via in inlet port 124. The inlet port 124 is in fluid communication with upstream components positioned on the engine cooling circuit, such as the valve 116. In some embodiments, the inlet port 124 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, bonded, pinned, etc.) to an end 121 (e.g., a sidewall, etc.—seen in FIG. 7 ) of the shell 120. In other embodiments, the inlet port 124 is integrally formed with the end of the shell 120.

The heat exchanger assembly 118 also includes an outlet port 126. The outlet port 126 is in fluid communication with downstream components positioned on the engine cooling circuit. In some embodiments, the outlet port 126 is coupled (e.g., attached, fixed, welded, fastened, riveted, adhesively attached, bonded, pinned, etc.) to an other end 123 of the shell 120 opposite the end corresponding to the inlet port 124. In some embodiments, the outlet port 126 is integrally formed with the other end of the shell 120.

The heat exchanger assembly 118 includes a core 128. The core 128 is disposed within the inner cavity 122 and is structured to receive the working fluid. The working fluid is used for cooling the engine coolant fluid. For example, the engine coolant fluid that passes through the inner cavity 122 is heated by the engine. As the heated engine coolant liquid flows through the inner cavity 122, the heated engine coolant fluid contacts the core 128 and transfers heat to the working fluid flowing through the core 128. Therefore, the engine coolant fluid is cooled before being reaching the engine. According to various embodiments, the working fluid can include any of various types of fluids, such as, for example, a refrigerant (e.g., R245a or other low global warming potential (“GWP”) replacements), ethanol, toluene, other hydrocarbon-based working fluids, other hydrofluorocarbon-based working fluids, or water. In some embodiments, the core 128 receives the working fluid through a plurality of channels extending through the core 128.

As described above, the engine coolant fluid passes through the inner cavity 122. A portion of the engine coolant fluid flowing through the inner cavity 122 is defined as a main flow 130. The main flow 130 is configured to flow from the inlet port 124 to the outlet port 126 in a main flow direction 133. In this way, the outlet port 126 is configured to provide the main flow 130 (e.g., of coolant, of oil, etc.) to downstream components of the cooling system. However, in some embodiments, the main flow 130 may be configured to flow in a direction opposite of the main flow direction 133 (e.g., from the outlet port 126 to the inlet port 124, etc.).

The main flow 130 of engine coolant fluid flows along a main flow path 132. The main flow path 132 is defined as a space between the core 128 and the shell 120 and extends from the inlet port 124 to the outlet port 126. As the main flow 130 flows along the main flow path 132, the heated engine coolant fluid contacts the core 128 and transfers heat to the working fluid flowing through the core 128.

Although the main flow 130 flows along the main flow path 132, the main flow 130 may diverge from the main flow path 132. Particularly, the main flow 130 may diverge from the main flow path 132 to define a bypass flow 134. The bypass flow 134 of engine coolant fluid flows along a bypass flow path 136. In some embodiments, the bypass flow path 136 is a space between the end 125 of the core 128 closest to the inlet port 124 and the shell 120. Referring to FIG. 6 , the bypass flow path 136 extends upwardly from the main flow path 132 in a bypass flow direction 127 and around the core 128. In some embodiments, the bypass flow path 136 is perpendicular to the main flow path 132. In this way, the bypass flow path 136 diverges from the main flow path 132. Notably, because the bypass flow path 136 diverges from the main flow path 132 and extends in this way around the core 128, the core 128 is unable to facilitate heat transfer from the bypass flow 134 to the core 128.

Referring to FIGS. 2-6 , the heat exchanger assembly 118 includes a baffle 138 (e.g., plate, protrusion, etc.). In some embodiments, the baffle 138 is integrally formed with the core 128. However, the baffle 138 may alternatively be a separate component which is coupled to the core 128. The baffle 138 includes a base portion 140. The base portion 140 is coupled to or integrally formed with an end of the core 128. More particularly, the base portion 140 may be coupled to or integrally formed with the end 125 of the core 128 closest to the inlet port 124.

In some embodiments, the base portion 140 extends in a direction parallel to a surface of the end of the core 128. The base portion 140 may also be coupled to the core 128 at a predetermined location such as to reduce a gap between the core 128 and the shell 120. In this way, a diameter of the bypass flow path 136 is reduced in a portion 137 downstream of the baffle 138, thereby restricting the bypass flow 134 in the bypass flow direction. However, the baffle 138 may also be positioned such that the baffle 138 is separated from the shell 120 to reduce flow interference. In some embodiments, the base portion 140 is comprised of sheet metal. Accordingly, the base portion 140 may be more securely fastened to the core 128 as compared to other systems using rubber baffles, which may present installation challenges and may be dislodged during operation.

The baffle 138 includes a curved portion 142. The curved portion 142 extends from the base portion 140. Particularly, the curved portion 142 extends into the bypass flow path 136 of the engine coolant fluid and is concavely curved in the bypass flow direction 127. In this way, the curved portion 142 is structured to reduce (e.g., impede, restrict, etc.) the bypass flow 134 in the bypass flow direction 127 by reducing a size of the bypass flow path 136 (e.g., a diameter of the bypass flow path, a width of the bypass flow path, etc.) at the downstream portion 137 when compared to a portion 139 upstream of the baffle 138. For example, as the bypass flow 134 reaches the curved portion 142, a portion of the bypass flow 134 is received (e.g., concentrated, captured, collected, etc.) by the curved portion 142 and is impeded from continuing along the bypass flow path 136 to the downstream portion 137. Further, the curved portion 142 is structured to generate a vortex 131 in the bypass flow 134. Because the curved portion 142 generates the vortex in the bypass flow 134, the bypass flow 134 path is reduced at the downstream portion 137 when compared to the upstream portion 139. By generating the vortex 131 within the curvature of the curved portion 142, the curved portion 142 reduces the bypass flow 134 in the bypass flow direction 127. In this way, the bypass flow 134 of engine coolant fluid that does not contribute to heat transfer is reduced.

As described above, in the heat exchanger assembly 118 of FIGS. 2-6 the curved portion 142 is concavely curved in the bypass flow direction 127. By being concavely curved in the bypass flow direction 127, the curved portion 142 is structured to return at least a portion of the bypass flow 134 to the main flow path 132. For example, as the bypass flow 134 is received by the curved portion 142, the curved portion 142 is structured to generate, in the bypass flow 134, a region of pressure higher than a pressure of the main flow 130 of the engine coolant fluid. Accordingly, because the bypass flow 134 generally flows in a direction from a region of higher pressure to a region of lower pressure, the region of higher pressure reduces the bypass flow 134 in the bypass flow direction 127, and causes at least the portion of the bypass flow 134 to flow in the direction opposite the bypass flow direction (e.g., towards the main flow path 132, etc.). Further, the baffle 138 is structured to reduce a flow velocity of the bypass flow 134 in the bypass flow direction 127. As the curved portion 142 receives the bypass flow 134 and impedes the bypass flow 134 in the bypass flow direction 127, the flow velocity of the bypass flow 134 is reduced and the portion of the bypass flow 134 is returned to the main flow 130.

III. Configuration of Example Embodiments

While this specification contains various implementation details, these should not be construed as limitations on the scope of what may be claimed but rather as descriptions of features specific to particular implementations. Certain features described in this specification in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can, in some cases, be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.

As utilized herein, the terms “substantially,” “generally,” “approximately,” and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the appended claims.

The term “coupled” and the like, as used herein, mean the joining of two components directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two components or the two components and any additional intermediate components being integrally formed as a single unitary body with one another, with the two components, or with the two components and any additional intermediate components being attached to one another.

The terms “fluidly coupled to” and the like, as used herein, mean the two components or objects have a pathway formed between the two components or objects in which a fluid, such as air, reductant, an air-reductant mixture, exhaust gas, hydrocarbon, an air-hydrocarbon mixture, may flow, either with or without intervening components or objects. Examples of fluid couplings or configurations for enabling fluid communication may include piping, channels, or any other suitable components for enabling the flow of a fluid from one component or object to another.

It is important to note that the construction and arrangement of the various systems shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and/or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow.

Also, the term “or” is used, in the context of a list of elements, in its inclusive sense (and not in its exclusive sense) so that when used to connect a list of elements, the term “or” means one, some, or all of the elements in the list. Conjunctive language such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, Z, X and Y, X and Z, Y and Z, or X, Y, and Z (i.e., any combination of X, Y, and Z). Thus, such conjunctive language is not generally intended to imply that certain embodiments require at least one of X, at least one of Y, and at least one of Z to each be present, unless otherwise indicated.

Additionally, the use of ranges of values herein are inclusive of their maximum values and minimum values unless otherwise indicated. Furthermore, a range of values does not necessarily require the inclusion of intermediate values within the range of values unless otherwise indicated.

It is important to note that the construction and arrangement of the various systems and the operations according to various techniques shown in the various example implementations is illustrative only and not restrictive in character. All changes and modifications that come within the spirit and/or scope of the described implementations are desired to be protected. It should be understood that some features may not be necessary, and implementations lacking the various features may be contemplated as within the scope of the disclosure, the scope being defined by the claims that follow. 

1. A cooling system of an internal combustion engine system, the cooling system comprising: an engine cooling circuit for defining a flow path and direction for engine coolant fluid flowing through the internal combustion engine system; and a heat exchanger assembly positioned along the engine cooling circuit and structured to transfer heat from the engine coolant fluid to a working fluid, the heat exchanger assembly including: a shell defining an inner cavity, a core disposed within the inner cavity and structured to receive the working fluid, and a main flow path and a bypass flow path of the engine coolant fluid, the core comprising a baffle in the bypass flow path, the baffle including: a base portion coupled to an end of the core, and a curved portion extending from the base portion such that the curved portion impedes a bypass flow of engine coolant fluid from continuing along the bypass flow path.
 2. The cooling system according to claim 1, wherein the curved portion extends into the bypass flow path of the engine coolant fluid and is concavely curved in a bypass flow direction.
 3. The cooling system according to claim 2, wherein the curved portion is structured to generate, in the bypass flow, a region of pressure higher than a pressure of a main flow of the engine coolant fluid.
 4. The cooling system according to claim 2, wherein the curved portion is structured to generate a vortex in the bypass flow.
 5. The cooling system according to claim 2, wherein the curved portion is structured to reduce a size of the bypass flow downstream of the baffle.
 6. The cooling system according to claim 2, wherein the curved portion is structured to reduce a flow velocity of the bypass flow in the bypass flow direction.
 7. The cooling system according to claim 1, wherein the baffle is integrally formed with the core.
 8. The cooling system according to claim 1, wherein the base portion extends in a direction parallel to a surface of the end of the core.
 9. The cooling system according to claim 1, further comprising an inlet port fluidly coupled to the inner cavity and structured to provide the engine coolant fluid to the inner cavity, and an outlet port fluidly coupled to the inner cavity.
 10. An engine system, comprising: the cooling system according to any preceding claim; and an engine including an engine block and an engine overhead positioned along the engine cooling circuit downstream of the heat exchanger assembly.
 11. The engine system according to claim 10, further comprising a pump structured to circulate the engine coolant fluid through the engine cooling circuit.
 12. The engine system according to claim 10, further comprising a turbocharger positioned on the engine cooling circuit downstream of the engine.
 13. The engine system according to claim 12, further comprising a coolant reservoir positioned on the cooling circuit downstream of the turbocharger and structured to receive and store the engine coolant fluid.
 14. The engine system according to claim 10, further comprising a valve positioned on the cooling circuit upstream of the heat exchanger assembly and configured to manage the engine coolant fluid provided to the heat exchanger assembly. 